Grid tie solar system and a method

ABSTRACT

A grid tie system includes a plurality of solar panels, a plurality of inverters, wherein each of the inverters is in electrical communication with at least one of the solar panels to convert a direct current to an alternating current, wherein each of the inverters has an active state and an inactive state and at least one of the inverters includes a tracking component to track a maximum power point of at least one of the solar panels, and a controller in communication with at least one of the inverters for selectively toggling the at least one of the inverters between the active state and the inactive state.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to the following: U.S.Provisional Application Ser. No. 61/211,649 filed Apr. 1, 2009; U.S.Provisional Application Ser. No. 61/267,192 filed Dec. 7, 2009; and U.S.Provisional Application Ser. No. 61/304,036 filed Feb. 12, 2010. Each ofthe foregoing Applications is incorporated by reference herein in itsentirety.

FIELD OF THE INVENTION

The present invention relates generally to solar panels for generatingelectricity. More particularly, the invention is directed to a grid tieinverter system for tying an electrical current generated by a pluralityof solar panels into an electrical grid system and a method forcontrolling the same.

BACKGROUND OF THE INVENTION

A photovoltaic (PV) array is a linked collection of solar panels(modules), which are made of multiple interconnected solar cells thatconvert light energy into direct electrical current (DC), via thephotovoltaic effect. However, most commercial and residentialapplications of electricity require alternating electrical current (AC)that typically is provided by power generating facilities utilizingcoal, nuclear material, or water. Upon generating the alternatingcurrent, the power generating facilities transmit the generatedalternating current into an electrical grid system.

In order for most commercial and residential users to utilize theelectricity generated by the solar panels, the direct current from thesolar panels is typically transformed into alternating current. This isachieved by way of an electrical device known as an inverter, the outputof which is subsequently tied to the electrical grid system. In turn,the alternating current is distributed via the electrical grid system tocommercial and residential sites.

Currently, in the United States, a conventional solar panel string (forexample, consisting of cadmium telluride (CdTe) or amorphous silicon)comprises six solar panels which are wired in series, where each suchsolar panel string inherently operates at a voltage of approximately 372VDC with an operating current of 0.87 amps. A set of the series solarpanel strings is then wired in parallel to form a row, where a set ofthe rows form the solar array that produces a desired total current.

In general, regarding electrical safety for the general public, exposureto the public is regulated by the National Electrical Code (NEC), wherepeople are not to come in contact with voltages over 42 volts (V) (andfacilities are not to have a voltage above 600 V. Hence, many components(e.g., wire, fuses, and switches) are rated for operation up to andincluding the 600 V limit.

On the other hand, the National Electrical Safety Code (NESC) regulateselectrical generating and distributing facilities, wherein skilledworkers in such facilities may be exposed to high voltages that canexceed 600 volts.

Although much work has been done to generate direct current by way ofsolar panels and then to invert the direct current to alternatingcurrent for tie-in to the electrical grid, the solar industry has beenhindered by overall low power efficiency rates associated withconverting sunlight energy into useable alternating current byinverters.

It would be desirable to develop a grid tie system for tying a solararray to an electrical grid and a method of controlling the grid tiesystem, wherein the system and method maximize a harvesting of energyunder low light level conditions and a reliability of the system throughselective activation of an inverter of the system.

SUMMARY OF THE INVENTION

Concordant and consistent with the present invention, a grid tie systemfor tying a solar array to an electric grid and a method of controllingthe grid tie system, wherein the system and method maximize a harvestingof energy under low light level conditions and a reliability of thesystem through selective activation an inverter of the system, hassurprisingly been discovered.

In one embodiment, a grid tie system comprises: a plurality of solarpanels; a plurality of inverters, wherein each of the inverters is inelectrical communication with at least one of the solar panels toconvert a direct current to an alternating current, wherein each of theinverters has an active state and an inactive state and at least one ofthe inverters includes a tracking component to track a maximum powerpoint of at least one of the solar panels; and a controller incommunication with at least one of the inverters for selectivelytoggling the at least one of the inverters between the active state andthe inactive state.

On another embodiment, a grid tie system comprises: a solar arrayincluding a plurality of panel strings in parallel electricalcommunication with each other, wherein each of the panel stringsincludes a plurality of solar panels; a direct current conduction bus inelectrical communication with each of the series wired panel strings; aplurality of inverters in electrical communication with the directcurrent bus ring to receive a direct current generated by the solararray and to convert the direct current to an alternating current,wherein each of the inverters has an active state and an inactive stateand at least one of the inverters tracks a maximum power point of atleast one of the solar panels; a controller in communication with eachof the inverters to receive a feedback signal from each of the invertersand toggle at least one of the inverters between the active state andthe inactive state based upon an analysis of each of the feedbacksignals, wherein the feedback signal includes information about anoperational characteristic of an associated one of the inverters.

The invention also includes methods of controlling a grid tie system.

One method comprises the steps of: providing a plurality of solarpanels; providing a plurality of inverters, each of the inverters inelectrical communication with at least one of the solar panels toreceive a direct current therefrom and to convert the direct current toan alternating current, wherein each of the inverters has an activestate and an inactive state and at least one of the inverters tracks amaximum power point of at least one of the solar panels; generating afeedback signal including information about an operationalcharacteristic of at least one of the inverters; analyzing the feedbacksignal; and toggling at least one of the inverters between the activestate and the inactive state in response to the analysis of the feedbacksignal.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present invention, willbecome readily apparent to those skilled in the art from the followingdetailed description of the preferred embodiment when considered in thelight of the accompanying drawings in which:

FIG. 1A is a schematic representation of a grid tie system according toan embodiment of the present invention;

FIG. 1B is a top plan view of the grid tie system of FIG. 1A;

FIG. 1C is a perspective view of the grid tie system of FIG. 1A;

FIG. 2 is a schematic representation of a series string of the grid tiesystem of FIGS. 1A-1C;

FIG. 3 is a schematic representation of a disconnect box of the grid tiesystem of FIGS. 1A-1C;

FIG. 4 is a schematic representation of a first clamping circuit of thegrid tie system of FIGS. 1A-1C;

FIG. 5 is a schematic representation of a second clamping circuit of thegrid tie system of FIGS. 1A-1C;

FIG. 6 is a schematic representation of a third clamping circuit of thegrid tie system of FIGS. 1A-1C;

FIG. 7 is a graphical representation of electrical characteristics of asolar panel during a “one sun” illumination;

FIG. 8 is a graphical representation of electrical characteristics of asolar panel during a varying illumination;

FIG. 9 is a graphical representation of electrical characteristics ofthe grid tie system of FIGS. 1A-1C, showing a dynamic toggling of aplurality of inverters;

FIG. 10 is a schematic representation of a grid tie system according toanother embodiment of the present invention;

FIG. 11 is a schematic representation of a grid tie system according toanother embodiment of the present invention;

FIG. 12A is a perspective view of a transformer of the grid tie systemof FIG. 11; and

FIG. 12B is a side elevational view of the transformer of FIG. 12A.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The following detailed description and appended drawings describe andillustrate various embodiments of the invention. The description anddrawings serve to enable one skilled in the art to make and use theinvention, and are not intended to limit the scope of the invention inany manner. In respect of the methods disclosed, the steps presented areexemplary in nature, and thus, the order of the steps is not necessaryor critical.

FIGS. 1A-1C and 2 illustrate a grid tie system 10 (also known as a gridtie solar system or grid tie photovoltaic (PV) system) for harvestingsolar energy according to an embodiment of the present invention. Asshown, the system 10 includes two portions 12 a, 12 b, each of whichincludes a plurality of rows 14, wherein the rows 14 are collectivelyreferred to as a solar array. As a non-limiting example, each row 14includes a plurality of series strings 16.

As more clearly shown in FIG. 2, each of the strings 16 includes aplurality of solar panels 18 that are wired together in series. Thestrings 16 making up each of the rows 14 are wired together in parallel.In certain embodiments, each of the strings 16 includes six of the solarpanels 18 wired in series to operate at approximately a voltage of 372VDC, an operating current of 0.87 amps, and an open circuit voltage of500 VDC. In certain embodiments, each of the strings 16 includes eightof the solar panels 18 wired in series to operate at approximately avoltage of 496 VDC, an operating current of 1.16 amps, and an opencircuit voltage of 672 VDC. In certain embodiments, each of the strings16 includes ten of the solar panels 18 to operate at approximately avoltage of 620 VDC, a current of 2.03 amps, and at an open circuitvoltage of 840 VDC. It is understood that any number of the strings 16and the panels 18 can be used to form a solar array.

As a non-limiting example, each of the portions 12 a, 12 b includesforty-four of the rows 14, each of the rows 14 includes twenty of thestrings 16, and each of the strings 16 includes eight of the solarpanels 18. Accordingly, the system 10 includes eighty-eight of the rows14, wherein each of the rows 14 includes one hundred and sixty of thepanels 18. However, unless expressed otherwise, the present invention isnot limited by the number or configuration of the array portions 12 a,12 b, the rows 14, the strings 16, or the panels 18.

The system 10 further includes a direct current conduction bus 20 (DCbus) in electrical communication with each of the strings 16, aplurality of inverters 22 in electrical communication with the DC bus20, wherein each of the inverters 22 has an active state and an inactivestate, an alternating current conduction bus 24 (AC bus) in electricalcommunication with each of the inverters 22; an electrical transformer26 in communication with the AC bus 24 to receive an alternating currenttherefrom and step up the AC output voltage to match the distributionlines of an AC grid 28, and a controller 30 in communication with atleast one of the inverters 22 for selectively toggling the at least oneof the inverters 22 between the active state and the inactive state.

In the embodiment shown in FIGS. 1A-1C, the DC bus 20 is substantiallylinear. However, other configurations such as a ring shape can be used.Each of the rows 14 is electrically connected to the DC bus 20 in aparallel configuration to transmit a DC current therethrough. However,other electrical configurations can be used.

The inverters 22 are electrically coupled to the DC bus 20 to receive aDC current (input) and convert the DC current into an output AC current,wherein the AC current is transmitted to the AC bus 24. In certainembodiments, the direct wiring connection 57 from the DC bus 20 to a DCinput of each of the inverters 22 is no more than ten feet (threemeters) and the direct wiring from the output of each of the inverters22 to the AC bus 24 is by way of a “pig tail” cable 59 of approximatelyten feet. However, any configuration using any length of wiring betweenthe inverters 22, the DC bus 20, and the AC bus 24, can be used.

As a non-limiting example, at least one of the inverters 22 includes amaximum power point tracker (MPPT) 31 to track a maximum power point ofat least one of the solar panels 18. It is understood that the MPPT 31can be any type of control circuit, device, or logic to adjust thesettings of the inverter to search for a maximum power point and allowthe at least one of the inverters 22 to extract the maximum poweravailable from an associated device (i.e. the row 14, the string 16, thepanel 18, etc.).

The inverters 22 are utilized on an as-needed basis to convert the DCinput and transmit an output power. Any number of the inverters 22 areselectively toggled between an active state and an inactive state by thecontroller 30 (e.g. programmable logic controller (PLC)). As anon-limiting example, the controller 30 is in signal communication witheach of the inverters 22 by way of one or more RS485 serialcommunications protocol connectors (S1-S7). Other connectors andprotocols can be used. As a further non-limiting example, each of theinverters 22 includes an air inlet 32 for thermal management.

The AC bus 24 is substantially linear. However, other configurations canbe used. Each of the inverters 22 is electrically connected to the ACbus 24 in a parallel configuration to transmit an AC currenttherethrough. However, other electrical configurations can be used.

The AC bus 24 includes a contactor/disconnect 33 that conducts the ACcurrent to the transformer 26. It is understood that other switches andrelays can be used to conduct the AC current to the transformer 26. Thetransformer 26 steps up an input voltage so that an AC output voltagematches the distribution lines of the AC grid 28. In addition, thetransformer 26 galvanically isolates the inverters 22 from theelectrical AC grid 28, which provides protection against islanding.Although the embodiment shown in FIGS. 1A-1C includes one of thetransformers 26, it is understood that any number of the transformers 26can be used. It is further understood that the transformer 26 can beelectrically integrated in any position in the system 10 (e.g. loadside).

As a non-limiting example, a plurality of disconnect boxes 34 and aplurality of clamping circuits 36 a, 36 b, 36 c are disposed between therows 14 and the DC bus 20. Specifically, each of the disconnect boxes 34is disposed between at least one of the clamping circuits 36 a, 36 b, 36c and the DC bus 20. It is understood that any number of disconnectboxes 34 can be used.

As more clearly shown in FIG. 3, each of the disconnect boxes 34includes a double-pole, double-throw switch 38 interposed between theclamping circuit 36 a, 36 b, 36 c and the DC bus 20. Each of thedisconnect boxes 34 includes a plurality of protection devices. As anon-limiting example, the disconnect boxes 34 provide over-currentprotection by way of a plurality of fuses F₁, F₂ and lightningprotection is provided by way of a plurality of metal oxide varistorsMOV1, MOV2. It is understood that the placement of the disconnect boxes34 at an output of each of the rows 14 minimizes the need to disposefuses in each of the series strings 16, as conventional solar arraysrequire. It is further understood that the disconnect boxes 34 allow anyrow 14 to be disconnected from the DC bus ring 20 for service ormaintenance at any time.

At least one of the clamping circuits 36 a, 36 b, 36 c may be disposedbetween the rows 14 and the DC bus 20 to militate against a voltage ofgreater than 600 VDC being placed across the components within the solarpanels 18 (e.g. a situation when the AC grid 28 “goes down” in themiddle of a sunny day). In general, voltage clamping can be initiatedmanually, for example, in order to perform maintenance on an individualone of the rows 14 or when one or more of the rows 14 is/are notproducing enough DC output. Also, clamping could be automaticallycommanded by, for example, the controller 30. It is understood that theclamping circuits 36 a, 36 b, 36 c may be configured to clamp thevoltage to any pre-determined voltage such as 600VDC and 1000 VDC, forexample.

FIG. 4 illustrates the first clamping circuit 36 a including adouble-pole, double-throw switch 40. In a shorting position, thecontacts of a double-pole, double-throw switch 40 short an incomingpositive terminal from the output of an associated one of the rows 14 toan incoming negative terminal to place the associated one of the rows 14in a short circuit condition. The short circuit condition protects theoverall circuitry of the panels 18 from an overvoltage condition, forexample. Subsequently, when the associated one of the rows 14 is to bebrought back “on-line”, a controlling signal is received (eitherelectrically from the controller 30 or by mechanical means) to togglethe switch 40 to allow the DC output current of the row 14 to flow tothe DC bus 20 via one of the disconnect boxes 34.

FIG. 5 illustrates the second clamping circuit 36 b including agate-turn-off (GTO) thyristor 42 that is sized appropriately for themagnitude of the DC current lop being generated by one of the rows 14.With a controlling signal (e.g. from the controller 30) on a gate G ofthe thyristor 42, the output of the row 14 is short circuited asdescribed above for the first clamp circuit 34 a but with a 1 to 3 VDCdrop across the thyristor 42. Conversely, if a control signal is notpresent on the gate G, the DC current output of the row 14 is presentedto the input of an associated one of the disconnect box 38. When thethyristor 42 is conducting, a diode D1 prevents a short circuit of theentire system 10 by way of a DC bus ring 20, whereby the thyristor 42would likely be damaged.

FIG. 6 illustrates a third clamping circuit 34 c including adouble-pole, double-throw switch 44 much like that of switch 40.However, instead of directly short circuiting the positive terminal ofthe incoming output of an associated one of the rows 14 to the incomingnegative terminal, the third clamping circuit 36 c includes a resistor Rdisposed therebetween. Hence, the third clamping circuit 36 c functionssimilarly to that of the first clamping circuit 36 a but presents avoltage drop across the resistor R in order to limit a current thatwould flow therethrough. Subsequently, if a controlling signal isreceived (e.g. from the controller 30 or by mechanical means) thecontacts of the double-pole, double-throw switch 44 present the DCcurrent output of the row 14 to the input of a disconnect box 34.

Although it seems counter intuitive, when disconnecting one of the rows14 from supplying current to the system 10, it is better to cause thesolar panels 18 to be short circuited rather than to be open circuited.Hence, the clamping of, for example, one of the rows 14 of the strings16 minimizes the risk that the strings 16 experience a voltage that isgreater than 600 VDC when the strings 16 are experiencing an opencircuit condition, which is covered under the NEC.

However, in a fully secured solar array where only skilled utilityworkers have access, maintaining the maximum voltage of 600 VDC is notrequired. In this case, NESC standards apply. Also, in other locationsaround the world (for example, in Europe), solar arrays may have highervoltage levels, for example, up to 1000 VDC. Hence, voltage clamping maynot be necessary, depending on the material composition of the solarcell and its tolerance to the larger voltages.

In use, the system 10 generates a DC current that is transmitted via thedisconnect boxes 34 and clamping circuits 36 a, 36 b, 36 c to theinverters 22. The inverters 22 convert the DC current to an output ACcurrent which is transmitted to the transformer 26 via the AC bus 24.The transformer 26 provides galvanic isolation and voltage step-up (froma nominal 360 V AC to the distribution voltage, typically 12,500 V AC)for the received output of the inverters 22. In certain embodiments, thetransformer 26 provides separate impedance balanced primary windings foreach of the inverters 22.

It is understood that the cumulative operating current from each of thedisconnect boxes 34 is conducted, via the DC bus 20, to the inverters 22that are toggled to an “active” state. Specifically, the controller 30determines a path that the DC output currents by cooperating with theinverters 22 to pass information back and forth to selectively determinewhich of the inverters 22 are to be turned on and off. The controller 30effectively directs the DC current to a select number of the inverters22 for transforming the DC current to AC current to maximize the poweroutput of the system 10 and to reduce power losses within the system 10.The inverters 22 that are toggled to an “inactive” state are typicallydisconnected from the AC bus 24 and the AC grid 28 to minimize quiescentlosses, thereby maximizing an efficiency of the grid tie system 10.

FIGS. 7-8 illustrate a characteristic curve 46 of typical electricalcharacteristics of one of the solar panels 18, wherein I is current, Vis voltage, I_(sc) is short circuit current, I_(op) is operationcurrent, V_(op) is operational voltage, V_(oc) is open circuit voltage,and P_(max) is a maximum power point. In particular, FIG. 7 shows an IV(Current/Voltage) curve 48 of one of the solar panels 18 under “One Sun”illumination (i.e. the standard under which conventional solar panelsare rated.) It is understood that there is only one point (i.e. themaximum power point) on the IV curve where the product of voltage andcurrent (i.e. power) is maximized. As a non-limiting example, theoperating voltage (V_(op)) is about 20% less than the open-circuitvoltage (V_(oc)).

FIG. 8 illustrates a graphical representation 50 of the same one of thesolar panels 18 represented in FIG. 7 under varying illumination. Thecurrent varies in direct proportion to the solar level. However, theopen circuit voltage remains constant. Each of a plurality of IV curves52 has one point where the product of voltage and current is maximized(i.e. maximum power point).

When brought on-line, the inverters 22 utilize distributed control tocalculate an individual maximum power point (MPP) based upon a DC powerreceived from an associated number of the strings 16. For example, theinverters 22 are controlled based upon a traditional “perturb andobserve” algorithm. When the DC power output of a connected number ofthe series strings 16 exceeds the collective capacity of the inverters22 that are connected at a particular time, then the controller 30toggles more of the inverters 22 to an “active” state. In turn, each ofthe inverters 22 that is toggled to an “Active” state determines anindividual MPP that is utilized by that particular one of the inverters22, while leaving the other ones of the inverters 22 that are alreadyonline at essentially their maximum current point Imax. In this way, thelast of the inverters 22 on-line is regulating the operating voltage ofthe system 10 (via the DC bus 20), while the remaining inverters 22continue to invert the maximum current from their respective portion ofthe DC bus 20. As a result, each of the inverters 22 determines andsafely handles its own current at any given time, while minimizingresistive losses of the incoming current. In addition, each of theinverter 22 provides its own anti-islanding protection.

As an illustrative example, FIG. 9 shows a depiction of a dynamictoggling of the inverters 22 based on a summer day in Toledo, Ohio. Aplurality of dashed lines represent an 85% power level for each of theinverters 22, wherein at least a pair of the inverters 22 share a loadproportionally. As the DC power output of the collective rows 14 variesthroughout the day, any number of the inverters 22 can be toggledbetween the “active” and “inactive” state to share the load.

Compared to conventional solar arrays, which have inverters directlywired to individual rows, the DC bus 20 allows for any combination ofthe inverters 22 to be utilized in a virtually equal manner forinverting the collective DC output current of the rows 14 into an ACcurrent that is conducted to the AC bus 24. It is understood that amajor benefit of the present invention is the transmission of a lowerelectrical current at a higher voltage, thereby minimizing a gage ofrequired wiring and connecting devices, which consequently minimizesconstruction and maintenance costs.

As a non-limiting example, the strings 16 include CdTe series-wiredsolar panels 18 (e.g. manufactured by First Solar, Incorporated ofPhoenix, Ariz.) and have a nominal operation voltage on the order of 496VDC to produce power on the order of 575 W. Where each row 14 includestwenty of the strings 16, wherein each of the strings 16 includes eightpanels 18 wired in series to generate a current on the order of 23 A DCand 11.5 KW of power. Hence, the transformer 26 would be presented witha voltage of 360 VAC—three phase, which is transformed on the utilityside (i.e., on the side of the grid 28) of the transformer 26 to 12,470V/7,200 V—three phase. It is understood that the output of the system 10is in contrast to the conventional six panel wired in series that wouldpresent 277 VAC—three phase.

As a further example, where each of the strings 16 includes ten of thepanels 18, the nominal operational voltage would be in the order of 620VDC which would produce power in the order of 719 W. Where each row 14includes sixteen of the series strings 16 an output current in on theorder of 18.6A DC and 11.5 KW of power. The transformer 26 would bepresented with a voltage of 480 VAC—three phase, which is transformed onthe utility side (the grid 28) of the transformer 26 to the 12,470V/7,200 V—three phase.

Although the above specific examples are directed to CdTe series strings16, the same trends and limits noted would exist for any type of solarpanels 18 wired in series/parallel strings 16, 16′, for example,amorphous silicon panels.

FIG. 10 illustrates a grid tie system 100, also known as a grid tiesolar system or grid tie photovoltaic (PV) system, according to anotherembodiment of the present invention similar to the system 10, except asdescribed herein below. As shown, the system 100 includes two portions102 a, 102 b each of which includes a plurality of rows 104. As anon-limiting example, each of the rows 104 includes a plurality ofseries strings 106. Each of the strings 106 includes a plurality ofsolar panels 108 that are wired together in series. The strings 106making up each of the rows 104 are wired together in parallel. It isunderstood that any number of stings 106 and panels 108 can be used toform a solar array.

The solar array 100 further includes a direct current conduction bus 110(DC bus) in electrical communication with each of the series wired panelstrings 106, a plurality of inverters 112 disposed adjacent the DC bus110 and electrically coupled thereto, wherein each of the inverters 112has an active state and an inactive state, an alternating currentconduction bus 114 (AC bus) in electrical communication with each of theinverters 112; an electrical transformer 116 in communication with theAC bus 114 to receive an alternating current therefrom and step up theAC output voltage to match the distribution lines of an AC grid 118, anda controller 120 in communication with at least one of the inverters 112for selectively toggling the at least one of the inverters 112 betweenthe active state and the inactive state.

The DC bus 110 is substantially ring shaped. However, otherconfigurations such as a horseshoe shape can be used. Each of the rows104 is electrically connected to the DC bus 110 in a parallelconfiguration to transmit a DC current therethrough. However, otherelectrical configurations can be used.

The inverters 112 are electrically coupled to the DC bus 110 to receivea DC current (input) and convert the DC current into an output ACcurrent. As a non-limiting example, at least one of the inverters 112includes a maximum power point tracker (MPPT) 121 to track a maximumpower point of at least one of the solar panels 108. It is understoodthat the MPPT 121 can be any type of control circuit or logic to searchfor a maximum power point and allow the at least one of the inverters112 to extract the maximum power available from an associated device(i.e. the row 104, the string 106, the panel 108, etc.).

The inverters 112 are utilized on an as-needed basis to convert the DCinput and transmit an output power. In certain embodiments, any numberof the inverters 112 are selectively toggled between an active state andan inactive state by the controller 120 (e.g. programmable logiccontroller (PLC)). As a non-limiting example, the controller 120 is insignal communication with each of the inverters 112 by way of RS485serial communications protocol connectors (S1-S8). Other connectors andprotocols can be used. It is understood that by centrally locating theinverters 112 within the ring of the DC bus 110, a wire gauge used forinterconnection between the inverters 112 and the DC bus 110 isminimized.

The AC bus 114 is substantially horseshoe shaped. However, otherconfigurations such as a ring shape can be used. Each of the inverters112 is electrically connected to the AC bus 114 in a parallelconfiguration to transmit an AC current therethrough. However, otherelectrical configurations can be used.

The AC bus 114 includes a contactor/disconnect 122 that conducts the ACcurrent to the transformer 116. It is understood that other switches andrelays can be used to conduct the DC current to the transformer 116. Thetransformer 116 steps up an input voltage so that an AC output voltagematches the distribution lines of the AC grid 118. Instead of multipletransformers (i.e., one transformer on the output of each of theconventional inverters), as conventional solar arrays require, thesingle large utility scale transformer 116 steps up the AC outputvoltage to match the distribution lines of the AC grid 118. In addition,the single transformer 116 galvanically isolates the inverters 112 fromthe electrical AC grid 118, which provides protection against islanding.

As a non-limiting example, a plurality of disconnect boxes 124 and aplurality of clamping circuits 126 a, 126 b, 126 c are disposed betweenthe rows 104 and the DC bus 110. Specifically, each of the disconnectboxes 124 is disposed between at least one of the clamping circuits 126a, 126 b, 126 c and the DC bus 110. It is understood that any number ofdisconnect boxes 124 can be used. It is understood that the placement ofthe disconnect boxes 124 at an output of each of the rows 104 minimizesthe need to dispose fuses in each of the series strings 106, asconventional solar arrays require. It is further understood that thedisconnect boxes 124 allow any row 104 to be disconnected from the DCbus ring 110 for service or maintenance at any time.

The clamping circuits 124 a, 124 b, 124 c may be disposed between therows 104 and the DC bus 110 to militate against a open circuit voltageof greater than 600 VDC being placed across the components within thesolar panels 108 such as a situation when the AC grid 118 were to “godown” in the middle of a sunny day. In general, voltage clamping can beinitiated manually, for example, in order to perform maintenance on anindividual row or when one of the rows 104 is not producing enough DCoutput. Also, clamping could be automatically commanded by, for example,the controller 120. In certain embodiments, a disconnect box is disposebetween the clamping circuit 124 a, 124 b, 124 c and the DC bus 110.

In use, the solar panels 108 generate a DC voltage in response toexposure to solar energy. At least one of the inverters 112 senses thepresence of the generated DC voltage and draws an electrical currentwhich causes the DC voltage of at least one of the solar panels 108 todrop. On a very fast timeline (e.g. every two seconds) the at least oneinverter 112 executes a “perturb and observe” routine to locate amaximum power point of at least one of the solar panels 108. It isunderstood that the “perturb and observe” routine may include varying avoltage and measuring a change in a resultant current. It is furtherunderstood that any “perturb and observe” routine or algorithm can beused. Once the maximum power point is determined, the at least one ofthe inverters 112 “locks” onto the maximum power point by maintainingthe voltage-to-current ratio, conventionally referred to as maximumpower point tracking. The inverters 112 convert the DC current to anoutput AC current which is transmitted to the transformer 112. Thetransformer 116 provides galvanic isolation and voltage step-up (from anominal 360 V AC to the distribution voltage, typically 12,500 V AC) forthe received output of the inverters 112. In certain embodiments, thetransformer 116 provides separate impedance balanced primary windingsfor each of the inverters 112.

FIG. 11 illustrates a solar array 200, also known as a grid tie solarsystem or grid tie photovoltaic (PV) system, according to anotherembodiment of the present invention similar to the grid tie system 10.The grid tie system 200 includes a plurality of solar panels 202 (e.g.arranged in series to form solar strings). In certain embodiments, thesolar panels 202 are connected in parallel to a DC bus 204 and inelectrical communication with a plurality of inverters 206. It isunderstood that any number of the solar panels 202 and the inverters 206can be used. It is further understood that any electrical configurationcan be used. As a non-limiting example, the solar panels 202 and theinverters 206 are arranged in a configuration similar to theconfiguration of the system 10 or the system 100.

The inverters 206 are electrically coupled to the solar panels 202 toreceive a DC current (input) and convert the DC current into an outputAC current. As a non-limiting example, at least one of the inverters 206includes a maximum power point tracker (MPPT) 207 to track a maximumpower point of at least one of the solar panels 202. It is understoodthat the MPPT 207 can be any type of control circuit or logic to searchfor a maximum power point and allow the at least one of the inverters206 to extract the maximum power available from an associated device(i.e. any number of the solar panels 202).

As shown a circuit 208 is interposed between at least one of the solarpanels 202 and at least one of the inverters 206. As a non-limitingexample, the circuit 208 includes a disconnect box (not shown) similarto the disconnect box 34 of the system 10. As a further non-limitingexample, the circuit 208 includes a clamping circuit (not shown) similarto one of the clamping circuits 36 a, 36 b, 36 c of the system 10. It isunderstood that any number of the circuits 208 can be used.

The inverters 206 are utilized on an as-needed basis to convert the DCinput and transmit an output power. In certain embodiments, any numberof the inverters 206 are selectively toggled between an active state andan inactive state by a controller 209 (e.g. programmable logiccontroller (PLC)).

As shown, the grid tie system 200 further includes at least onetransformer 210 coupled to an output of each of the inverters 206. As anon-limiting example, the transformer 210 is a delta-wye isolationtransformer having a plurality of electrically parallel delta primarywindings and a wye secondary winding. Each of the delta primary windingsis electrically coupled to an AC output of one of the inverters 206 andthe secondary winding is electrically coupled to a distribution line. Incertain embodiments, the transformer 210 is similar to the utilitytransformer shown and described in U.S. Provisional Pat. Appl. Ser. No.61/267,192.

FIGS. 12A and 12B illustrate the transformer 210 according to anembodiment of the present invention. As shown, the transformer is adelta-wye isolation transformer having a plurality of electricallyparallel delta primary windings and a wye secondary winding. Each of thedelta primary windings is electrically coupled to an AC output of one ofthe inverters 206 via at least one of a plurality of primary connectors214. The secondary winding is electrically coupled to a distributionline via at least one of a plurality of secondary connectors 216. It isunderstood that various electrical connections between the inverters,the transformer, and the distribution line to the grid can providevarious step-up transformations.

In use, the solar panels 202 generate a DC voltage in response toexposure to solar energy. At least one of the inverters 206 senses thepresence of the generated DC voltage and draws an electrical currentwhich causes the DC voltage of at least one of the solar panels 202 todrop. On a pre-determined timeline (e.g. every two seconds) the at leastone inverter 206 executes a “perturb and observe” routine to locate amaximum power point of the solar panels 202. It is understood that theperturb and observe routine may include varying a voltage and measuringa change in a resultant current. It is further understood that anyperturb and observe routine or algorithm can be used. Once the maximumpower point is determined, the at least one of the inverters 206 “locks”onto the maximum power point by maintaining the voltage-to-currentratio, conventionally referred to as maximum power point tracking.

In certain embodiments, the inverters 206 are toggled from an inactivestate to an active state on an “as needed” basis in response to apre-determined and variable power level. Ideally, only one of theinverters 206 manages the maximum power point for the entire system 200,as described above. The controller 209 selectively toggles one of theinverters 206 (referred to as a master inverter 212) into an activestate. As a non-limiting example, each of the inverters 206 includes anembedded component (e.g. control circuit) in communication with thecontroller 209 to transmit a feedback signal to the controller 209having information relating to an operating characteristic or history ofan associated one of the inverters 206. As a further example, thefeedback signal includes information relating to: an inverter “timeonline”; an inverter mode (controllable from the controller 209: maximumpower point tracking mode or a specific current output); a current outreading; a DC voltage In reading; an AC voltage in reading; anerror/faults experienced by the inverter; a power produced year to date;and a power produced (by month, day, hour, minute, etc.). It isunderstood that in order to establish a hierarchy of the selection ofthe inverters 14, the controller 209 queries each of the inverters 206,receives a feedback signal therefrom, and analyzes the informationrepresented by the feedback signal to select a master inverter from thequeried inverters 206. Typically, the controller 209 is pre-programmedto select the one of the inverters 206 having the lowest “time online”.However, the controller 209 can be programmed to select the masterinverter 212 based upon any parameters or analysis.

Once selected, the master inverter 212 is the one of the inverters 206that manages the maximum power point for the system 200 for apre-determined time period. When additional ones of the inverters 206(referred to as non-master inverters 213) are toggled into an activestate, the additional non-master inverters 213 draw current; however,the master inverter 212 continues to track the maximum power point ofthe solar panels 202.

As a non-limiting example, the master inverter 212 that is managing themaximum power point (MPP) is capable of running to a limit of 150 KVA at(240 A). The master inverter 212 is driven until approximately 80% ofthe 240 A limit is reached. At that point the next one of the non-masterinverters 213 in the hierarchy (typically determined based upon thequery by the controller 209), is toggled to an active state and drivento approximately 80% of an associated current limit (240 A). It isunderstood that any percentage of the current or power limit can be usedas a threshold value. Simultaneously, the master inverter 212 isadjusted to approximately 20% of the 240 A limit to maintain managementof the MPP. The master inverter 212 continues to track the maximum powerpoint until again the master inverter 212 is driven to approximately 80%of the 240 A limit. At that point, the next one of the non-masterinverters 213 in the hierarchy is toggled to an active state and drivento approximately 80% of an associated limit. The master inverter 212continues to manage the MPP, while the active non-master inverters 213cooperate with the master inverter 212 to manage or “digest” theavailable current. As the master inverter 212 reaches approximately 80%of the current limit, one of the active non-master inverters 213 (e.g.the second one of the inverters 206 to be activated) is driven to nearly100% of the current limit, the MPP is monitored, and the level of themaster inverter 212 is modified by changing an output of at least one ofthe non-master inverters 213. It is understood that on a day withintermittent cloud cover, the solar power will vary throughout the day.Accordingly, a time constant or threshold is introduced to eliminateexcessive toggling and switching of the inverters 206.

The “active” inverters 206 are adjusted to receive a DC current, convertthe DC current to an output AC current, and transmit the AC current tothe transformer 210. The transformer 210 combines two functions into onepackage. The primary function of the transformer 210 is to providegalvanic isolation and voltage step-up (from a nominal 360 VAC to thedistribution voltage, typically 12,500 VAC) for the received output ofthe inverters 210. The secondary function of the transformer 210 is toprovide separate impedance balanced primary windings for each of theinverters 206.

The grid tie system 200 including the controller 209 effectively“rotates” the inverters 206 to maintain nearly equal running hoursbetween each of the inverters 206 in the system 200. Accordingly, thegrid tie system 200 and method of controlling the system 200: maximizesa harvest of energy under low light level conditions; maximizes areliability by selectively toggling each of the inverters 206 on an“as-needed” basis; and re-routes power in the event of a failure of oneof the inverters 206.

In the fields of electrical generation and distribution, where exposureto 600 V or greater are regulated by the NESC, and in countries wherefacilities may exceed the 600 V limit (for example, 1000 VDC), the eightor ten solar panels being wired in series provide approximately 30%higher voltage than conventional grid tie solar systems, whichtranslates into higher efficiencies with lower gage wire sizes (i.e., atleast one AWG copper wire size less than that required for theconventional six series wired panel string). Also, the capacities ofother conductor items are comparably lower/smaller since they arerequired to handle only a lower current (i.e., lower cost of systemmaterials and lower electrical losses experienced), thereby resulting inapproximately the same AC power output (e.g., 1 MW, 250 KW, 125 KW, etc)from the system 10, 100, 200, where generally a solar array is providedto produce a set amount of power in accordance with Ohm's Law (P=I×V).

In the present invention, since the inverters 22, 112, 206 may beswitched on and off on an as-needed basis, the accumulated runtime ofeach inverter 22, 112, 206 is greatly reduced. For example, in an arealike Toledo, Ohio, which has an abundance of overcast and partiallycloudy weather, each inverter 22, 112, 206 of the present invention mayonly be utilized for 7.5 years of the 20 year life span of a solararray, as opposed to the life span of inverters of a conventional solararray which are typically on continuously throughout the life of aconventional solar array. Also, in the present invention, if an inverter22, 112, 206 fails, the remaining inverters 22, 112, 206 will pick upthe output current. In the conventional solar array, if an inverter isdefective, it must be replaced in order to collect the output currentfrom the rows that are wired to that particular inverter.

It is also known that, in general, inverters are most efficient whenthey are running at or near their peak power rating. For a conventionalsolar array, where an inverter is only operating at 10% of rated power,the inverter may only be 85% efficient. In the present invention, theinverters 22, 112, 206 that would currently be turned on wouldconsistently deliver energy at or greater than 96% efficiency.

Operating the inverters 22, 112, 206 on an as-needed-basis lowers costsand results in improving the inverter efficiency rates, for example, theinverters can be taken off-line at night. Also, interstage andinter-inverter transformers are not disposed with the inverters 22, 112,206 of the present invention, thus resulting in lowering equipment,installation, and maintenance costs. In short, the present inventionresults in fewer components within the system 10, 100, 200, whichtranslates into higher power efficiencies.

From the foregoing description, one ordinarily skilled in the art caneasily ascertain the essential characteristics of this invention and,without departing from the spirit and scope thereof, make variouschanges and modifications to the invention to adapt it to various usagesand conditions.

What is claimed is:
 1. A grid tie system for a solar array including aplurality of solar panel strings, each of the solar panel stringsincluding a plurality of solar panels connected in series for generatinga DC power output comprising: a DC bus for receiving the DC power outputfrom the solar panels; a plurality of disconnect boxes spaced along alength of the DC bus, each of the disconnect boxes disposed between theDC bus and an associated one of the solar panel strings to provideselective electrical communication therebetween; a plurality ofinverters, wherein each of the inverters has an input in electricalcommunication with the DC bus and an output for converting the DC poweroutput to an AC power output, wherein each of the inverters has anactive state and an inactive state and includes a maximum power pointtracker to track a maximum power point of at least one of the solarpanels, the input of each of the inverters being directly connected tothe DC bus by wiring; and a controller in communication with theinverters for selectively toggling the inverters between the activestate and the inactive state while maintaining at least one of theinverters in the active state to maximize the AC power output and reducepower losses within the grid tie system, the controller responding tothe DC power output of the solar panels exceeding a collective capacityof the inverters operating in the active state to toggle another one ofthe inverters in the inactive state to the active state, the maximumpower point tracker of the another one inverter determining a maximumpower point for operation of the another one inverter to regulate anoperating voltage of the DC bus while all others of the inverters in theactive state each operate at an associated maximum current point.
 2. Thegrid tie system according to claim 1, further comprising a clampingcircuit disposed between the at least one of the solar panels and the DCbus to limit a voltage across the at least one of the solar panels. 3.The grid tie system according to claim 2, wherein the clamping circuitincludes at least one of a double pole, double throw switch and athyristor to toggle the circuit to a short circuit condition.
 4. Thegrid tie system according to claim 1, further comprising an electricaltransformer in communication with an electrical grid and the invertersto receive the AC power output from the inverters and step-up a voltageof the AC power output to match a voltage of the grid.
 5. The grid tiesystem according to claim 4, further comprising an AC bus in electricalcommunication between an output of each of the inverters and an input ofthe transformer to transmit the AC power output from the inverters tothe transformer.
 6. The grid tie system according to claim 1, whereinthe inverters execute a “perturb and observe” routine to track themaximum power point of the at least one of the solar panels.
 7. The gridtie system according to claim 1, wherein the inverters transmit afeedback signal to the controller, the feedback signal representing anoperational characteristic of the inverters, and wherein the controllertoggles the inverters between the active state and the inactive statebased upon an analysis of the feedback signal.
 8. A grid tie systemcomprising: a solar array including a plurality of panel strings inparallel electrical communication with each other, wherein each of thepanel strings includes a plurality of solar panels connected in series;a direct current bus in electrical communication with each of the panelstrings for receiving a direct current power output from the solarpanels; a plurality of disconnect boxes spaced along a length of thedirect current bus, each of the disconnect boxes disposed between thedirect current bus and an associated one of the panel strings to provideselective electrical communication therebetween; a plurality ofinverters each with an input in electrical communication with the directcurrent bus to receive the direct current power output generated by thesolar array and to convert the direct current power output to analternating current power output, wherein each of the inverters has anactive state and an inactive state and includes a maximum power pointtracker that tracks a maximum power point of at least one of the solarpanels, the input of each one of the inverters being directly connectedto the DC bus by wiring; and a controller in communication with each ofthe inverters to receive a feedback signal from each of the invertersand to toggle the inverters between the active state and the inactivestate while maintaining at least one of the inverters in the activestate based upon an analysis of each of the feedback signals, whereineach of the feedback signals includes information about an operationalcharacteristic of an associated one of the inverters, the controllerresponding to the direct current power output of the solar panelsexceeding a collective capacity of the inverters operating in the activestate to toggle another one of the inverters in the inactive state tothe active state, the maximum power point tracker of the another oneinverter determining a maximum power point for operation of the anotherone inverter to regulate an operating voltage of the direct current buswhile all others of the inverters in the active state each operate at anassociated maximum current point.
 9. The grid tie system according toclaim 8, further comprising a clamping circuit disposed between thedirect current bus and at least one of the panel strings to limit avoltage generated by the at least one of the panel strings.
 10. The gridtie system according to claim 8, further comprising an electricaltransformer in communication with an electrical grid and the invertersto receive the alternating current power output from inverters andstep-up a voltage of the alternating current power output to match avoltage of the grid.
 11. The grid tie system according to claim 10,wherein the transformer includes a separate impedance balanced primarywinding for each of the inverters.
 12. The grid tie system according toclaim 8, wherein at least one of the inverters executes a “perturb andobserve” routine to locate a maximum power point of at least one of thesolar panels.
 13. The grid tie system according to claim 8, wherein thedirect current bus is generally ring shaped.
 14. A method of controllinga grid tie system, the method comprising the steps of: providing aplurality of solar panels connected to a DC bus and generating a DCpower output from the solar panels to the DC bus, the solar panels beingconnected in series in a plurality solar panel strings; providing aplurality of disconnect boxes spaced along a length of the DC bus, eachof the disconnect boxes disposed between the DC bus and an associatedone of the solar panel strings to provide selective electricalcommunication therebetween; providing a plurality of inverters, each ofthe inverters being in electrical communication with the DC bus toreceive the DC power output and to convert the DC power output to an ACpower output, wherein each of the inverters has an active state and aninactive state and includes a maximum power point tracker that tracks amaximum power point of at least one of the solar panels, an input ofeach of the inverters being directly connected to the DC bus by wiring;generating a feedback signal including information about an operationalcharacteristic of the inverters; analyzing the feedback signal; andtoggling the inverters between the active state and the inactive statein response to the analysis of the feedback signal while at least one ofthe inverters is in the active state, the controller responding to theDC power output of the solar panels exceeding a collective capacity ofthe inverters operating in the active state to toggle another one of theinverters in the inactive state to the active state, the maximum powerpoint tracker of the another one inverter determining a maximum powerpoint for operation of the another one inverter to regulate an operatingvoltage of the DC bus while all others of the inverters in the activestate each operate at an associated maximum current point.
 15. Themethod according to claim 14, further comprising the step of providingan AC bus in electrical communication with each of the inverters toreceive the AC power output.
 16. The method according to claim 14,further comprising the step of transforming the AC power output to matcha voltage of an electrical grid.
 17. The method according to claim 14,wherein at least one of the inverters executes a “perturb and observe”routine to locate a maximum power point of at least one of the solarpanels.